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  • New fuel pump wiring harness question

    I installed my new fuel pump (155215) and also got the new wiring harness (501000). The wiring harness converts the 2 wire (grey and black) into a 4 wire harness (2 black and 2 grey) to run the duel pumps inside the new fuel pump assembly. The connector on one side of the new harness has 2 pins and the other side has 4 pins. The yellow connector on the new fuel pump has the mating 4-pin connector.

    My problem is the old yellow connector on the old fuel pump has 3 pins (grey, black and green). The green wire comes from the harness that goes to the fuel gauge meter. Using the new 4 wire harness leaves the green wire with no place to be connected to. Has anyone upgraded their fuel pump and used this new 4 wire harness? If so, what did you do with the green wire?
    Attached Files
    2002, X30, L-18, Red Metal Flake (the possessed boat)

  • #2
    It’s been a few years since I installed mine, but I’m pretty sure the green wire is just left disconnected. I received emailed instructions, but I don’t have access to that computer right now.

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    • #3
      Originally posted by rgardjr View Post
      It’s been a few years since I installed mine, but I’m pretty sure the green wire is just left disconnected. I received emailed instructions, but I don’t have access to that computer right now.
      The only green wire I know of near the tank is a ground wire, which IS supposed to be connected, as a way to prevent sparks from static electricity.

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      • #4
        Originally posted by JimN View Post
        The only green wire I know of near the tank is a ground wire, which IS supposed to be connected, as a way to prevent sparks from static electricity.
        I was thinking of connecting it to the grounding blade on the top of the regulator.
        2002, X30, L-18, Red Metal Flake (the possessed boat)

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        • #5
          Don’t remember which wire it was but I remember also having one left over connection that I just didn’t use when I installed my new fuel module. Not sure if I did it the right way but it works. Would also like to know what we are supposed to do with it.

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          • #6
            I traced the green wire in the old original fuel pump and it's definitely a ground. It bolts to the underside of the fuel pump top plate. So it appears to be a fuel pump chassis ground. Should I cut the green wire out of the original connector and terminate it with a shade connector and attached it to the blade coming off of the new fuel pump's regulator? See the picture below of the new fuel pump and you can see the blade attached to the top of the regualator.
            Attached Files
            2002, X30, L-18, Red Metal Flake (the possessed boat)

            Comment


            • #7
              Just got off the phone with Inboard Garage. They confirmed the green wire from the original wiring harness does get connected to the blade on top of the regulator of the new fuel pump.

              I can't say enough great things about these guys. They had the part and shipped it out within a day. They are very knowledgeable on all things MC. I will definitely go back for parts and knowledge needs. Unfortunately, they are several thousand miles from me so taking the boat for service is not in the cards.

              Keep up the great work Inboard Garage (www.inboardgarage.com).
              2002, X30, L-18, Red Metal Flake (the possessed boat)

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              • #8
                I went back through my emails and here's the instructions I received from Charlotte Ski Boats back in 2014:

                "Below is the wiring harness instructions.



                The new harness adapter has 2- 12 volt wires and 2 ground wires. You will have to cut the original fuel pump harness plug off. Splice the 12 volt wire to both 12 volt wires on the new harness. Splice the ground to both ground wires on the new harness.

                If there is a green wire on the old fuel pump plug that runs over to the fuel fill- cut it, it is not needed.

                This is not hard, Tech should be able to look at it and know what to do.

                **Disclaimer: It is recommended that you have a trained technician install this harness and pump. Charlotte Ski Boats will not be held responsible for fire or explosion due to improper installation.

                Thanks,

                Chris

                “Your MasterCraft Parts Guy”"

                I will take a look at my regulator the next weekend and see if there is a tab to hook up the green ground to.
                2006 Maristar 200 SS

                Comment


                • #9
                  Has anyone shortened the fuel pump wiring harness? Both the original and now my new one are 8 feet long. I only need about 2.5 feet. They probably make them 8 feet long because they use the same harness on direct drive boats that have to go from the engine harness to the back of the boat to the fuel tank. I don't really want to cut out 6.5 feet and slice it back together. I would rather de-pin the connector that goes into the pump, cut out 6.5 feet and re-pin the connector. Anyone every done this? Is there a special tool to get the sockets out of the connector?
                  2002, X30, L-18, Red Metal Flake (the possessed boat)

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                  • #10
                    can you post a quick pic of the end of the connector?

                    id also have no qualms about cutting and shortening if using some small bare crimps, the right crimpers, and good impregnated heatshrink
                    and stagger the cuts a little to not have a clump of splices in one spot

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                    • #11
                      Originally posted by ValveCoverGasket View Post
                      can you post a quick pic of the end of the connector?

                      id also have no qualms about cutting and shortening if using some small bare crimps, the right crimpers, and good impregnated heatshrink
                      and stagger the cuts a little to not have a clump of splices in one spot
                      Here is a picture of the original connector. The new one is identical but has 4 wires instead of two.

                      Yeah, I could cut with wires and stagger the slices but I thought if it easy to de-pin it would look a little more professional (MCOCD kicking in).
                      Attached Files
                      2002, X30, L-18, Red Metal Flake (the possessed boat)

                      Comment


                      • #12
                        Found it.
                        https://www.amazon.com/Delphi-Metri-...360005&sr=8-15

                        The connector at the end of the wiring harness is a Metri-Pack 150, 4 cavity female sockets. I'm going to give this a spin.
                        2002, X30, L-18, Red Metal Flake (the possessed boat)

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                        • #13
                          What did you end up doing with the extra wire?

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                          • #14
                            yup that one oughta do it! you can buy the knockoffs in multi packs - check ebay also - no need to pay $20 for that...

                            there is a thicker version (blue handle) thats better for slightly more prying the green ones like the break pretty easily.

                            also, for crimping the new ones it should be a two part op, the seal with the round and the wire with the fold over.
                            using something like this (again, buy cheaper knockoffs since youre not using these day in and day out..)
                            https://www.amazon.com/Metri-Pack-Cr.../dp/B011TNNNKK

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                            • #15
                              Originally posted by mrm2083 View Post
                              What did you end up doing with the extra wire?
                              Nothing yet. Have done the mod to the wiring harness.
                              2002, X30, L-18, Red Metal Flake (the possessed boat)

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